Wire spool repair device and method of using same

ABSTRACT

The present invention advantageously provides a wire spool repair device for a damaged wire spool having a central cylindrical portion with an axial bore and inner cylinder surface and a pair of opposing end plates attached thereto, the repair device including: an end plate, an attachment mechanism disposed on said end plate, a plurality of gripping fingers pivotally attached to said attachment mechanism and operative between retracted and attachment positions, and wherein insertion of said attachment mechanism into the axial bore of a wire spool and pivoting of said plurality of gripping fingers to the attachment position causes said plurality of gripping fingers to move into contacting relationship with the inner cylinder surface of the wire spool thereby attaching the repair device to the wire spool.

FIELD OF THE INVENTION

The present invention relates to repair devices for wire spools, andmore specifically, to wire spool repair devices having a replacement endplate with an integrated wire spool attachment mechanism.

BACKGROUND OF THE INVENTION

The terms wire and cable are used to refer to any computer or electricalwire or cable. Wires and cables may be sold in discrete or bulk lengths.When sold in discrete lengths, an excess of wire or cable typicallyexists for any particular job, and this excess wire or cable can quicklybecome an expensive, unsightly and inconvenient mess. To remedy thisproblem, wire or cable is also sold in bulk, which is typically sold ona spool and can be expensive. Although expensive, wire sold on spoolsprevents the waste associated with discrete lengths of wire.

A typical wire spool has a central cylindrical portion, about which alength of wire is wound and carried. The cylindrical portion has anaxial bore and opposing axial ends. Each axial end of the cylindricalportion is attached to opposing circular end plates. The end platesprevent the wire from unraveling over the axial ends of the centralcylindrical portion. Multiple wire spools may be mounted on a spoolrack. The spool rack is generally a frame having a plurality of wirespool mounting rods. A wire spool is typically situated on a mountingrod of a wire spool rack by sliding the axial bore of the wire spoolcentral cylindrical portion onto such mounting rod. A spool racktypically carries multiple spools of wire having varying gauges in orderto efficiently manage and retain multiple gauges of wire by an end userin the field, which represents a significant investment of operatorfunds.

In use, when an operator needs a length of wire, the operator grabs thetype and gauge desired and the wire is unraveled from the wire spool.Specifically, the spool spins about the mounting rod via the centralcylindrical portion as the operator dispenses wire in a radialdirection. Due to the wear and tear of everyday use of wire spools onracks in the field, the spools tend to fail and become damaged andunusable. More specifically, often times one of the end plates retainingthe wire on the spool will crack or break off. When this happens thespool becomes very cumbersome to work with and the wire is difficult tounload from the spool. For example, wire can get caught in a crack of anend plate or unravel axially from the spool over a broken off portion ofthe end plate, instead of a radial direction, and get bound up withother spools on the rack. To manage this problem, broken wire spools aretypically disposed of and the remaining wire on that spool is wasted,which is a highly undesirable business expense.

It would therefore be beneficial to provide a repair device for acracked or broken wire spool end plate that overcomes the problems inthe art. It would also be beneficial to provide a repair device for awire spool end plate that is detachable and reusable, as broken wirespools are a repeating problem in the industry. This invention addressesthat need and advantageously overcomes the deficiencies of the priorart.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a repair device fora damaged wire spool that overcomes the disadvantages of the prior art.

Accordingly, the present invention advantageously provides a wire spoolrepair device for a damaged wire spool having a central cylindricalportion with an axial bore and inner cylinder surface and a pair ofopposing end plates attached thereto, the repair device including: anend plate, an attachment mechanism disposed on said end plate, aplurality of gripping fingers pivotally attached to said attachmentmechanism and operative between retracted and attachment positions, andwherein insertion of said attachment mechanism into an axial bore of thewire spool and pivoting of said plurality of gripping fingers to theattachment position causes said plurality of gripping fingers to moveinto contacting relationship with the inner cylinder surface of the wirespool thereby attaching the repair device to the wire spool.

It is a feature of the present invention that the repair device includesan attachment mechanism with gripping fingers being pivotally operablebetween retracted and attachment positions and thereby allow forrepeated use of the repair device.

It is an object of the present invention that the repair device endplate has a peripheral annular lip, which is adapted to overlap andcontain a damaged end plate of a wire spool when the attachmentmechanism is inserted as described above.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other objects, advantages, and features of the presentinvention will become apparent from a reading of the following detaileddescription with reference to the accompanying drawings, in which:

FIG. 1 is a perspective view of a damaged wire spool according to thepresent invention;

FIG. 2 is a perspective view of a wire spool repair device according tothe present invention;

FIG. 3 is an exploded side view of a wire spool repair device accordingto the present invention;

FIG. 4 is an exploded perspective view of an attachment mechanism of awire spool repair device according to the present invention;

FIG. 5 is a side view of a wire spool repair device situated adjacent adamaged wire spool according to the present invention;

FIG. 6 is a side view of a wire spool repair device inserted into anaxial bore of a damaged wire spool according to the present invention;and

FIG. 7 is a side view of a wire spool repair device inserted into anaxial bore of a damaged wire spool and operatively attached theretoaccording to the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

The present invention discloses a wire spool repair device 18 used torepair a damaged wire spool 10. Generally referring to FIGS. 1-7, a wirespool 10 has a central cylindrical portion 16, about which a length ofwire (not shown) is wound and carried, as is known in the art. Thecentral cylindrical portion 16 has an axial bore 58 and an innercylinder surface 62. Attached to each axial end of the cylindricalportion 16 are opposing circular end plates, 12 and 14. The end plates,12 and 14, serve to prevent the wire from unraveling over the axial endsof the central cylindrical portion 16. Multiple wire spools 10 can bemounted on a spool rack (not shown), for use in the field by anoperator. A spool rack is generally a frame having a plurality of wirespool mounting rods for receiving a plurality of wire spools. Due to theeveryday wear and tear to wire spools in the field, it is often the casethat an end plate 14 will crack or break and render the wire spool 10unusable. This disadvantageously requires an operator to remove thedamaged spool 10 from the spool rack and discard the spool therebywasting time and money.

Referring to FIGS. 2-7, the present invention generally discloses a wirespool repair device 18 that is adapted to attach directly to a damagedwire spool 10. The repair device 18 essentially permits an operator toadvantageously cure a cracked or broken end plate 14, which is arecurring problem. Repairing a broken end plate 14 allows the operatorto leave the damaged wire spool 10 on the spool rack thereby saving theoperator time and money on replacing the spool and wasting unused wire.Once the wire is used up on the damaged wire spool 10, the operatoradvantageously detaches and reuses the repair device 18, while thebroken wire spool 10 may be discarded or recycled as desired. The repairdevice 18 generally includes a replacement end plate 20 having anattachment mechanism 26 disposed thereon.

As best shown in FIGS. 2 & 3, the replacement end plate 20 is generallycircular and has an axial bore 24 of predetermined diameter. Thereplacement end plate also has a peripheral annular lip 22 defining arecessed area in the end plate 20, which is adapted to nestingly receivea damaged end plate 14 of a wire spool 10. The axial bore 24 ispreferably of a diameter suitably adapted to work in conjunction with astandard mounting rod of a wire rack (not shown), as are known in theart. The annular lip 22 serves to over lap and contain the damaged endplate 14 (see FIGS. 1, 5, 6 and 7) thereby preventing wire from gettingcaught or hung up on the damaged portion of the end plate 14. Thereplacement end plate 20 is preferably composed of a polymeric material,as is known in the art, but may be made of other suitable materialswithout departing from the scope of the present invention.

As generally shown in FIGS. 2-7, the repair device 18 has an attachmentmechanism 26 disposed thereon. Referring to FIGS. 3 and 4 in particular,the attachment mechanism 26 further includes a spreader base 28,spreader drive body 40, and drive plate 46. The spreader base 28 has aplurality of gripping fingers 36 pivotally attached 34 thereto. Asdiscussed in greater detail below, in use, the gripping fingers 36 arepivotally operative between retracted and attachment positions, as shownin FIGS. 6 and 7 respectively. When the repair device 18 is mated to adamaged wire spool 10 and the gripping fingers 36 are pivoted to theattachment position (see FIG. 7), the gripping fingers 36 come intocontacting relationship with the inner cylinder surface of the damagedwire spool 10. This contacting relationship holds the replacement endplate 20 adjacent to the damaged end plate 14, thereby effectivelyrepairing the damage to the wire spool 10. Attachment of the repairdevice 18 to the damaged wire spool 10 in such a way, advantageouslyallows the operator to continue using the wire spool and save money onwasted wire or cable and overcomes the problems associated with theprior art.

More specifically, Referring to FIGS. 2-7, the attachment mechanism 26has a spreader base 28, spreader drive body 40, and drive plate 46. Thespreader base 28 has a plurality of gripping fingers 36 pivotallyattached 34 thereto. The spreader base 28 has an axial base bore 30,adapted to receive a wire rack mounting rod, and guide channels 32adapted to receive a plurality of pivotally operable gripping fingers36. The guide channels 32 pivotally retain and guide the pivotingmovement of the gripping fingers 36. The gripping fingers 36 may beattached to the spreader base 28 in the guide channels 32 with aconventional pivot pin 34 or other suitable means, as are known in theart. The pivot pin 34 may be advantageously spring loaded so as to biasthe gripping fingers 36 to the retracted position (see FIGS. 5 and 6).The gripping fingers 36 have a spreader face 38, having a predeterminedangle, adjacent a gripping surface 56. The gripping surface 56 ispreferably a ‘high coefficient of friction type’ material (i.e., rubber)or device (i.e., teeth or abrasive surface). Regardless of the materialor device used for the gripping surface 56, it is desired the grippingsurface 56 will resist the relative lateral or radial motion of thecentral cylindrical portion 16 with respect to the repair device 18,when the gripping fingers 18 are manipulated to the attachment position(see FIG. 7). The spreader base 28 may be attached to the replacementend plate 20 with standard, bolt and screw type, adjustable fasteners 54and the like, as are known in the art.

Furthermore, especially with respect to FIGS. 3 and 4, the attachmentmechanism 26 includes a spreader drive body 40 and a drive plate 46. Thedrive body 40 has a substantially conical spreader face 42 and an axialdrive body bore 44, which is adapted to receive a mounting rod of a wirespool rack (not shown). The drive body 40 is preferably composed of alightweight polymeric material, but may be made of other suitablematerials without departing from the scope of the present invention. Inorder to enhance the strength of the light weight drive body 40 andprovide a force dispersing surface for the attachment mechanism 26; adrive plate 46 is rigidly attached 52 (i.e., rivets or other suitabledevice) to the drive body 40. The drive plate 46 has an axial driveplate bore 48 substantially the same as the base bore 30 and drive bodybore 44, and when taken together define a bore suitably adapted formating with a mounting rod of a wire spool rack (not shown). Adjustmentmounts 50 (i.e., stop nuts with nylon inserts and the like), work inconjunction with elongate adjustment rods 54 (i.e., threaded bolts andthe like) to manually adjust the axial position of the spreader drivebody 40 with respect to the spreader base 28.

More specifically, operator manipulation of the adjustment rods 54causes an axial force to be applied to the attachment mounts 50. Theaxial force of the attachment mounts 50 in contact with the drive plate46 causes the drive plate 46 to urge the spreader drive body 40 axiallytoward the spreader base 28. Eventually the axial movement of thespreader drive body 40 toward the spreader base 28, will cause theconical spreader face 42 to come into sliding contacting relationshipwith the spreader faces 38 of the gripping fingers 36. Preferably, theconical spreader face 42 is angled substantially symmetrically oppositeto the angled spreader faces 38. Continued axial movement of thespreader drive body 40 toward the spreader drive base 28 causes slidingcontact between the conical spreader face 42 and the gripping fingerspreader faces 38, thereby causing the gripping fingers 36 to pivotoutwardly 60 and between retracted and attachment positions as shown inFIGS. 6 and 7 respectively. In essence, axial movement of the spreaderdrive body 40 translates into pivotal movement 60 of the grippingfingers 36 between retracted and attachment positions (see FIGS. 6 and 7respectively), thereby advantageously providing an operator with adetachable and reusable repair device 18.

Even more specifically, when in use the attachment mechanism 26 of therepair device 18 is inserted into the axial cylinder bore 58 of thedamaged wire spool 10 (see FIGS. 5 and 6) such that the replacement endplate 20 is in abutting and overlapping relationship with the damagedend plate 14 and the attachment mechanism 26 is substantially within theaxial cylinder bore 58. Preferably, the attachment mechanism 26 isinserted adjacent the inner cylinder surface 62, and substantiallysurrounded by the central cylindrical portion 16. Once the repair device18 is inserted thusly, the repair device 18 is operated as describedabove, and the gripping fingers 36 pivot radially to the attachmentposition (see FIG. 7). When the gripping fingers 36 are pivoted to theattachment position, the gripping fingers 36 come into contactingrelationship with the inner cylinder surface 62, thereby attaching therepair device 18 to a damaged wire spool 10. Conversely, pivoting thegripping fingers 36 to the retracted position (see FIG. 6) allows therepair device 18 to be detached and reused.

While only one embodiment has been illustrated and described in detail,it should be understood that various modifications in design and detailsof construction are possible without departing from the spirit of thisinvention or the scope of the following claims.

1. A wire spool repair device for a damaged wire spool having a centralcylindrical portion with an axial bore and inner cylinder surface, and apair of opposing end plates attached thereto, the repair devicecomprising: an end plate; an attachment mechanism disposed on said endplate; and a plurality of gripping fingers pivotally attached to saidattachment mechanism and operative between retracted and attachmentpositions.
 2. The repair device of claim 1, wherein the attachmentmechanism further includes a spreader base adjacent to said end plate.3. The repair device of claim 2, wherein said spreader base has theplurality of gripping fingers pivotally attached thereto.
 4. The repairdevice of claim 3, wherein said plurality of gripping fingers each hasan angled spreader face, said fingers operative between retracted andattachment positions.
 5. The repair device of claim 4, wherein saidplurality of gripping fingers each has a gripping surface adjacent tosaid angled spreader face.
 6. The repair device of claim 5, wherein theattachment mechanism further includes a spreader drive body disposedadjacent to said spreader base.
 7. The repair device of claim 6, whereinsaid spreader drive body has a substantially conical spreader face. 8.The repair device of claim 7, wherein axial translation of the spreaderdrive body toward the spreader base causes said angled spreader faces ofthe gripping fingers to come into sliding contact with said conicalspreader face thereby causing the gripping fingers to pivot to saidattachment position.
 9. The repair device of claim 6, wherein thespreader base and spreader drive body each have an axial bore.
 10. Therepair device of claim 1, wherein when said attachment mechanism isinserted into the axial bore of a wire spool and said plurality ofgripping fingers are pivoted to the attachment position, the pluralityof gripping fingers are in contacting relationship with the innercylinder surface of the wire spool.
 11. The repair device of claim 1,wherein when said attachment mechanism is inserted into the axial boreof a wire spool and the gripping fingers are in the attachment position,the end plate is adjacent and abutting an end plate of a wire spool. 12.A wire spool repair device for a damaged wire spool having a centralcylindrical portion with an axial bore and inner cylinder surface, and apair of opposing end plates attached thereto, the repair devicecomprising: an end plate; an attachment mechanism disposed on said endplate having a spreader base and a spreader drive body with asubstantially conical spreader face; a plurality of gripping fingerspivotally attached to said spreader base, each having an angled spreaderface, said fingers operative between retracted and attachment positions;and wherein axial translation of said drive body brings said conicalspreader face into sliding contacting relationship with said angledspreader face of said gripping fingers whereby said plurality ofgripping fingers are pivoted outward to said attachment position. 13.The repair device of claim 12, wherein said plurality of grippingfingers each has a gripping surface adjacent to said angled spreaderface.
 14. The repair device of claim 12, wherein the spreader base andspreader drive body each have an axial bore.
 15. The repair device ofclaim 12, wherein when said attachment mechanism is inserted into theaxial bore of a wire spool and said plurality of gripping fingers arepivoted to the attachment position, the plurality of gripping fingersare in contacting relationship with the inner cylinder surface of thewire spool.
 16. The repair device of claim 12, wherein when saidattachment mechanism is inserted into the axial bore of a wire spool andthe gripping fingers are in the attachment position, the end plate isadjacent and abutting an end plate of a wire spool.
 17. A wire spoolrepair device for a damaged wire spool having a central cylindricalportion with an axial bore and inner cylinder surface, and a pair ofopposing end plates attached thereto, the repair device comprising: anend plate; an attachment mechanism disposed on said end plate having aspreader base and a spreader drive body with a substantially conicalspreader face wherein the spreader base and spreader drive body eachhave an axial bore; a plurality of gripping fingers pivotally attachedto said spreader base, each having an angled spreader face and agripping surface adjacent to said angled spreader face, said fingersoperative between retracted and attachment positions; and wherein axialtranslation of said drive body brings said conical spreader face intosliding contacting relationship with said angled spreader face of saidgripping fingers whereby said plurality of gripping fingers are pivotedoutward to said attachment position.
 18. The repair device of claim 17,wherein when said attachment mechanism is inserted into the axial boreof a wire spool and said plurality of gripping fingers are pivoted tothe attachment position, the plurality of gripping fingers are incontacting relationship with the inner cylinder surface of the wirespool.
 19. The repair device of claim 17, wherein when said attachmentmechanism is inserted into the axial bore of a wire spool and thegripping fingers are in the attachment position, the end plate isadjacent an end plate of a wire spool.
 20. The repair device of claim17, wherein said end plate further includes an annular lip adapted tooverlap and contain a wire spool end plate when the attachment mechanismis inserted into the axial bore of a wire spool and said repair deviceend plate is adjacent the wire spool end plate.